U.S. patent application number 16/869539 was filed with the patent office on 2021-01-21 for immersion systems & methods for pre-washing or washing silverware.
The applicant listed for this patent is Immersion Systems, Inc.. Invention is credited to John Cantrell, Richard Powers, Roger Shealy.
Application Number | 20210015336 16/869539 |
Document ID | / |
Family ID | 1000005163743 |
Filed Date | 2021-01-21 |
![](/patent/app/20210015336/US20210015336A1-20210121-D00000.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00001.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00002.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00003.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00004.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00005.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00006.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00007.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00008.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00009.png)
![](/patent/app/20210015336/US20210015336A1-20210121-D00010.png)
United States Patent
Application |
20210015336 |
Kind Code |
A1 |
Cantrell; John ; et
al. |
January 21, 2021 |
Immersion Systems & Methods for Pre-Washing or Washing
Silverware
Abstract
A silverware pre-washing and washing system made up of a unitary
basin with one to five, and preferably three, vertically movable
porous baskets arranged radially around a central vertical lifting
and lowering mechanism. The base with unitary basin contains a
quantity of washing fluid(s) into which each of the vertically
movable porous baskets may be repeatedly immersed. The base cover
defines cylindrical ports through which the baskets are raised and
lowered. The porous baskets include perforation arrays to allow
washing fluid to flow in non-linear paths through the silverware
contained in the basket, thereby washing all sides of the
silverware and beneficially re-arranging the silverware in the
basket as the washing process proceeds.
Inventors: |
Cantrell; John; (Prairie
Village, KS) ; Powers; Richard; (Overland Park,
KS) ; Shealy; Roger; (Fayetteville, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Immersion Systems, Inc. |
Topeka |
KS |
US |
|
|
Family ID: |
1000005163743 |
Appl. No.: |
16/869539 |
Filed: |
May 7, 2020 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62844385 |
May 7, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47L 15/246 20130101;
A47L 15/4287 20130101; A47L 15/449 20130101; A47L 15/4293 20130101;
A47L 15/0018 20130101; A47L 15/4244 20130101 |
International
Class: |
A47L 15/24 20060101
A47L015/24; A47L 15/00 20060101 A47L015/00; A47L 15/42 20060101
A47L015/42; A47L 15/44 20060101 A47L015/44 |
Claims
1. A mechanical system for creating a cycling, substantially
vertical, linear motion for introducing and removing a mass of
objects to and from a body of fluid; said mechanical system
positioned in proximity to a structure for holding the body of
fluid; a substantially vertical structure associated with the
mechanical system; at least one permeable structure for holding a
mass of objects; said at least one permeable structure being
associated with the substantially vertical structure; and said at
least one permeable structure being open to accept the loading of
objects during the cycling operation of the mechanical system.
2. The system as in claim 1 including a control means in operable
communication with the mechanical system.
3. The system as in claim 2 wherein objects are introduced to and
removed from the body of fluid as determined by a control means
that is programmable.
4. The system as in claim 1 wherein the at least one permeable
structure becomes partially submersed during the washing
process.
5. The system as in claim 1 wherein the at least one permeable
structure becomes fully submersed during the washing process.
6. The system as in claim 1 wherein the at least one permeable
structure is raised above the body of washing fluid.
7. The system as in claim 1 wherein multiple masses of objects in
the at least one permeable structure are introduced to and removed
from the body of fluid.
8. The system as in claim 1 wherein the body of fluid is
temperature controlled.
9. The system as in claim 1 wherein the entire system is of a size
and shape where it will fit onto, and be in operation on, existing
dish tabling.
10. The system of claim 1 further comprising indicator displays
associated with each permeable structure to provide process control
information to the user.
11. The system of claim 8 wherein the temperature is controlled
with a heating element positioned in thermal contact with the body
of fluid.
12. The system of claim 1 further comprising an overflow prevention
means to drain away excess fluid from the structure for holding
fluid.
13. The system of claim 1 further comprising a means for
introducing chemical additives into the body of fluid.
14. The system of claim 1 further comprising a means for
controlling a flow of fluid into the structure for holding fluid
and a flow of fluid out from the structure for holding fluid.
15. The system of claim 1 further incorporating indicator lights to
direct the sequential loading of the permeable structures.
16. The system of claim 1 further incorporating indicator lights to
indicate cycle completion, full load and overload conditions.
17. The system of claim 2 wherein the level of the body of fluid,
its temperature, and its chemical composition are controlled by a
programmable means as objects are introduced and/or removed.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit under Title 35 United
States Code .sctn. 119(e) of U.S. Provisional Patent Application
Ser. No. 62/844,385; Filed: May 7, 2019 the full disclosure of
which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates generally to systems and
methods for washing objects. The present invention relates more
specifically to immersion and agitation systems and methods for
washing multiple loose items such as silverware and table ware
(predominantly sets of forks, knives, and spoons) and performing
other tasks where the process of immersing and agitating the items
in a body of fluid would have benefit.
2. Description of the Related Art
[0003] Silverware pre-washing and washing systems currently
available generally use complex, expensive, and high maintenance
pumping systems and structures. These systems are heavy, expensive
and generally require complex installations or in some cases do not
integrate easily into existing end user operations. Other
challenges for existing systems include their general operation in
only one direction which tends to heavily wash one side of the
silverware and not thoroughly wash the other side of the
silverware. Such systems also typically lock the silverware down
into one position within layers which can preclude some areas of
the silverware from getting washed. A system that would offer a
full bidirectional washing action and at the same time continually
rearrange the silverware for proper, complete and thorough
pre-washing and washing would be a major advancement over the prior
art.
SUMMARY OF THE INVENTION
[0004] There exists a need for a system that can wash or pre-wash
silverware where complex and expensive pumping and manifold systems
and structures are not required and system weight, cost and
installation complexity are greatly reduced. It would be desirable
for such a system to easily integrate into an end users existing
operation and require minimal training for proper usage to be
achieved. A system that can be added to an existing operation by
simply placing it onto existing dish room tabling as opposed to any
type of more complex or less integrated installation, is optimal.
It would also be beneficial to have a system that offers large
amounts of processing capacity and the ability to sort the various
types of silverware for those end users that desire to do so.
[0005] In fulfillment of these and other objectives the present
invention provides a unitary basin with one to five, and preferably
three, vertically movable porous baskets arranged radially around a
central vertical lifting and lowering mechanism. The base with
unitary basin contains a quantity of washing fluid(s) into which
each of the vertically movable porous baskets may be repeatedly
immersed. The base cover defines cylindrical ports through which
the baskets are raised and lowered. The porous baskets include
perforation arrays to allow washing fluid to flow in non-linear
paths through the silverware contained in the basket, thereby
washing all sides of the silverware and beneficially re-arranging
the silverware in the basket as the washing process proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a three-basket embodiment of
the silverware washing system of the present invention with baskets
raised and empty.
[0007] FIG. 2 is a perspective view of the three-basket embodiment
of the silverware washing system of the present invention with the
baskets, guard, and lift mechanism cover removed for clarity.
[0008] FIG. 3 is a perspective rear view of the three-basket
embodiment of the silverware washing system of the present
invention with the lift mechanism cover removed for clarity.
[0009] FIG. 4 is a perspective bottom view of the three-basket
embodiment of the silverware washing system of the present
invention.
[0010] FIG. 5 is a perspective front view of the three-basket
embodiment of the silverware washing system of the present
invention with the water tub, guard, and center basket removed for
clarity.
[0011] FIG. 6A is a centerline cross-sectional view of the
three-basket embodiment of the silverware washing system of the
present invention with the lifting mechanism in a raised
condition.
[0012] FIG. 6B is a centerline cross-sectional view of the
three-basket embodiment of the silverware washing system of the
present invention with the lifting mechanism in a lowered
condition.
[0013] FIG. 7A is a perspective view of a typical installation of
two of the silverware washing systems of the present invention in a
food service facility with an adjacent fill faucet.
[0014] FIG. 7B is a perspective view of a typical installation of
two of the silverware washing systems of the present invention in a
food service facility with plumbed water supply lines and chemical
additive reservoirs.
[0015] FIG. 8 is a detailed perspective rear view of the drive and
lift mechanisms of the system of the present invention with the
covers removed for clarity.
[0016] FIG. 9 is a detailed perspective view of the control
elements of a typical installation of two of the silverware washing
systems of the present invention in a food service facility with an
adjacent fill faucet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The system that is contemplated by the inventors is one that
does not require heavy, complex pumping systems or manifold
structures, is easy and inexpensive to both install and use and
easily integrates into any end user operations. The elimination of
the above-mentioned complex pumping and manifold systems allows for
a system that can be light weight, compact and installed by simply
being set onto an end users existing dish table structure.
[0018] The invention utilizes a vertical structure that is
associated with a mechanical lift system and is further associated
with one or more permeable structures for holding a mass of
objects. This set of systems enables the mechanical system to raise
and lower the mass of objects into and out of a body of fluids.
This can be done at varying speeds and varied cycles based on the
pre-washing or washing task being performed. The action of
immersing the mass of objects into and out of the body of fluids
creates a powerful and comprehensive wash action as fluid rushes up
into and though the mass of objects and then via gravity rushes out
of the mass of objects as the objects pass through the fluid
surface. During this process objects are moved and rearranged by
the flow of the fluids and by being momentarily at least partially
levitated by that flow of fluids on the downward stroke of the
system.
[0019] It is important and critical to note that the system is
designed to operate safely while being fully open in order to allow
for loading of silverware (or other objects) into the system while
the system is fully in operation. It is further contemplated that
the system would employ a sensing system to determine when a full
load has been achieved and washing was complete at which time the
baskets would be delivered into an elevated position for unloading.
It is also anticipated that temperature sensing, fluid level
sensing, and total dissolved solids (TDS) sensing would be
incorporated as standard or optional features of the design.
[0020] In a preferred embodiment, the entire process of raising and
lowering the items into and out of the body of fluids is performed
and enabled by a variable speed, DC motor which is geared and
associated with a cam system and drive linkage. This preferred
embodiment is further associated with a programmable controller and
the above noted vertical structure and permeable structure for
holding objects. It is contemplated that further embodiments could
employ custom sizes and a multiplicity of permeable structures for
holding objects. While the current structure locates the DC motor
and gear box below the systems operating fluid level it could
alternatively be located above the systems operating fluid level
achieve the same results.
[0021] Reference is made to FIG. 1 for a perspective view of a
three-basket (or more generally, three-permeable structure) version
of the silverware washing system of the present invention. In this
view, the silverware washing system is shown to be made up of a
base and washing fluid tank with a washing fluid tank cover and a
centrally located reciprocating vertical motion device. In this
view, three porous baskets are shown in fully elevated positions,
generally above the surface of the washing fluid (not shown). The
base cover defines three cylindrical portals through which the
porous baskets are raised and lowered.
[0022] FIG. 1 is the view of the three-basket embodiment of the
silverware washing system of the present invention that the user
would encounter before beginning operation of the system with
baskets raised and empty. Immersion wash system 10 generally
comprises a system base 14 that supports an open top wash tank 16
that is partially covered with tank cover 18. To the rear of the
wash tank 16 is lift mechanism 22 that extends up from base frame
14. In the view of FIG. 1, the functional components of lift
mechanism 22 are enclosed within drive mechanism cover (and
support) 12 and lift mechanism cover 24. A movable basket holder
frame (hidden in FIG. 1) is operationally connected to lift
mechanism 22 and supports each of a number (three in the embodiment
shown) of porous baskets. In the three-basket embodiment shown,
baskets 20a-20c are shown positioned in the holder frame in the
elevated state. The diameter of the baskets is such as to just fit
within the respective circular ring support (described in more
detail below) forming part of the basket holder frame. In turn, the
openings in the tank cover 18 are just large enough to allow for
the removal and/or insertion of the removable baskets from the
basket holder frame. See FIG. 5 for more detail on the basket
holder frame.
[0023] Operational elements of the system additionally seen in FIG.
1 include: LED indicators 19a & 19b that may be used to
indicate the progress of steps in the wash cycling process; LED
indicators 21a-21c that may be used to alert the user to a proper
basket loading or unloading sequence; overflow tube 25 with drain
line/valve 26; and chemical feed line 23 (if applicable in the
particular embodiment). Once again, the functionality of each of
these components is described in more detail below.
[0024] Although the number of baskets in the system of the present
invention may be as few as one and as many as four or five or more,
the three-basket embodiment shown is advantageous for handling the
three typical types of tableware; forks, knives, and spoons. As
seen below, multiple units of the system of the present invention
may be preferred over a unit that exceeds three baskets as
positioning of the systems for ergonomic loading must be
considered. The baskets used may be any shape but are preferably
circular to facilitate a random alignment or misalignment of the
individual utensils in a manner that serves to prevent "nesting"
and therefore to better clean and rinse the silverware.
Additionally, the random loading of different types of silverware
into all three baskets may be desirable to further discourage any
type of "nesting" of the silverware. The baskets are preferably
wire mesh or molded plastic and have a porosity open enough to
allow for the easy flow of fluid through the basket while closed
enough to prevent the items of silverware from slipping through the
openings. The baskets preferably have handles (as shown in the
preferred embodiment) to permit the user to easily lift the basket
(empty or full) from the basket holder, potentially even while the
system is in operation. It is anticipated that the user will fill a
basket or add items of silverware (or other objects that require
washing) while the system is in operation. The LED indicators
21a-21c assist the user in identifying which baskets have been
washing the longest and which are best available for the addition
of silverware for washing as the system continues to operate. The
LED indicators 21a-21c may also be used to indicate which basket to
load at any given time.
[0025] The system structural components are preferably stainless
steel as is typical in commercial food preparation and food service
facilities. Tank cover 18 is preferably removable from wash tank 16
for periodic cleaning access to the submersible components of the
system and the interior of the wash tank 16 itself. Drive mechanism
cover (and support) 12 and lift mechanism cover 24 are also
preferable made of stainless steel components. As will be described
in more detail below, the system of the present invention is sized
and structured to be positioned on a table or other support
platform at approximately waist height for the users of the system.
At a minimum, the basic embodiment of the system requires an
external power connection while alternate embodiments further
include water line connections and/or chemical wash additive flow
line connections.
[0026] FIG. 2 is a perspective view of the three-basket embodiment
of the silverware washing system of the present invention with the
baskets, tank cover, and lift mechanism cover removed for clarity.
The functional components of the immersion wash system of the
present invention are again seen to generally comprise a system
base 14 that supports an open top wash tank 16 that, during
operation of the system, is partially covered with the tank cover
(removed in this view). To the rear of the wash tank 16 are the
components that make up the lift mechanism. The fixed components
are generally positioned exterior to the wash tank 16 while some of
the movable components extend inside of the wash tank 16. In FIG.
2, the rear frame portion of system base 14 in part helps secure
the lift components to the wash tank 16 structure, while the drive
mechanism cover (and support) and the lift mechanism cover (both
not shown in FIG. 2) additionally serve to position and support the
fixed components of the lift mechanism.
[0027] Of the lift mechanism components shown in FIG. 2, only the
bearing block 38 is fixed (with respect to the wash tank 16) while
lift rod 36, lift rod connector 34, actuator rods 32, and basket
holder frame 28, are all movable components of the lift mechanism.
As seen in FIG. 2, the three basket holders 30a-30c are fixed on
basket holder frame 28 and oriented to position the baskets (when
inserted into the holders) appropriately for the reciprocating
vertical motion they undergo in the washing process. Basket holder
frame 28 is fixed to the lower ends of actuator rods 32 which are
generally held in lateral position by the fixed position of bearing
block 38. Bearing block 38 allows for the free vertical motion of
the actuator rods 32 while keeping them (and all the components
attached to them) laterally positioned within wash tank 16.
[0028] Actuator rods 32 are fixed to basket holder frame 28 at
their lower end and to lift rod connector 34 at their upper end.
Lift rod connector 34 is pivotally secured to lift rod 36, which,
under direction of the drive components not seen in this view,
lifts and lowers the actuator rods 32 and therefore, by the
linkages described above, lifts and lowers the baskets supported in
the basket holders 30a-30c.
[0029] Additional components shown in FIG. 2 include overflow tube
25 positioned through the side wall of wash tank 16 at a height
just above the maximum desired fluid level in the tank, and drain
line/valve 26 positioned through the bottom wall of wash tank 16
and configured to drain the tank when desired. Once again, optional
chemical feed line 23 is shown extending down from an external
chemical additive reservoir (not shown) where the system utilizes
such chemical additives. Alternatively, the chemical additive
reservoir may also be located under the system. Not seen in FIG. 2
are the external power connection (described above as standard) and
an optional external water supply line.
[0030] Reference is next made to FIG. 3 which is a perspective rear
view of the three-basket embodiment of the silverware washing
system of the present invention with the lift mechanism cover and
the drive mechanism cover removed for clarity. In FIG. 3, system
base 14 is again seen to support the open top wash tank 16 which is
partially covered with tank cover 18. To the rear of the wash tank
16 is the rear frame portion of system base 14. In the three-basket
embodiment shown, baskets 20a-20c are positioned in the holder
frame (not visible in this view) in an elevated state. In the view
of FIG. 3, the functional components of the drive and lift
mechanisms are exposed where they are positioned and secured to the
rear frame portion of system base 14 and drive mechanism cover (and
support) (not shown in FIG. 3). Once again, the structures of
enclosure cover 40 and lift mechanism cover 24 further serve to
support and enclose the lift and drive mechanism components. As
described above in FIG. 2, actuator rods 32 are positioned through
bearing block 38 and extend downward to their point of attachment
to the basket holder frame (not visible in FIG. 3). The top ends of
actuator rods 32 are pivotally connected to lift rod 36 by way of
lift rod connector 34. Lift rod 36 serves as the linkage between
the drive mechanism of the system and the lift of the system.
[0031] The drive mechanism of the system is generally made up of DC
motor 42, gear box 46 and crank arm 44. DC motor 42 is powered from
an external source, typically from a remote (wall mounted)
controller as described in more detail below. DC motor 42 drives
the gears within gear box 46 which turn crank arm 44. Crank arm 44
is pivotally linked to lift rod 36 and moves lift rod 36 vertically
a distance approximately twice the length of crank arm 44. The
combination of DC motor 42 and gear box 46 are fixed within drive
mechanism cover (and support) 12 with enough clearance between gear
box 46 and enclosure cover 40 to allow for the free rotation of
crank arm 44 and its pivotal attachment to lift rod 36.
[0032] In addition to overflow tube 25 and drain line/valve 26
shown in FIG. 3, optional water and chemical additive flow lines
are shown. As shown, the drain valve 26 is manual, however, it may
also be an electric valve which would be controlled by the
controller. External water line 47 may be connected to a water
source (such as a typical commercial or residential pressurized
potable water supply) to provide a controlled filling of the wash
tank of the system. Auto fill valve 48 is preferably an electric
solenoid actuated valve that may be controlled by the same
controller that powers the DC motor 42. Water may flow directly
from auto fill valve 48 into wash tank 16 or, as shown in FIG. 3,
may pass through chemical inductor 45 before flowing into wash tank
16. Where used, chemical inductor 45 receives a flow of chemical
additive from a remote reservoir by way of chemical feed line 23.
The inductor incorporates various metering tips that have varying
orifice sizes to control the amount of chemical that is introduced
into the system. The auto-fill valve may also be set up to deliver
water to a third-party system (not shown in the figures) that mixes
the water with a chemical (typically a solid form of chemical that
dissolves) where it then flows to the wash tank. Various chemicals
may be added to the water within the system as may be desired for
assisting with the dissolving of food particles and other soils on
the silverware or sanitizing the wash bath after repeated use. Used
in conjunction with a solenoid-controlled drain line/valve 26, and
monitoring water conditions with sensors 50a & 50b, a flow of
chemicals through chemical fed line 23 can serve to help maintain
the tank fluid in optimal condition. It should be noted that the
wash system of the present invention is not intended to replace the
high temperature disinfecting wash and rinse that typically occurs
in a commercial foodservice dishwasher in a foodservice facility.
Rather the system of the present invention primarily serves a
pre-wash function that would typically be followed by a separate
disinfecting wash and rinse in a commercial foodservice
dishwasher.
[0033] FIG. 4 is a perspective bottom view of the three-basket
embodiment of the silverware washing system of the present
invention, structured as described above for placement on a typical
dish table or other platform of an appropriate height. As seen in
FIG. 4, system base 14 extends under and supports wash tank 16 with
associated tank cover 18 and further supports the drive and lift
mechanisms of the system (covered in the view of FIG. 4 with drive
mechanism cover (and support) 12 and lift mechanism cover 24).
External water line 47 is shown as it feeds through drive mechanism
cover 12 to the auto fill valve (not visible) of the water line
connected version of the system. Overflow tube 25 is shown exiting
through the side wall of wash tank 16 and drain line/valve 26 is
shown exiting from the bottom of wash tank 16. System base 14
provides enough clearance under wash tank 16 to facilitate this
placement of drain line/valve 26. Adjustable (leveling) base rubber
feet 35 are positioned on the cross member and legs of system base
14 to help retain the system in place when positioned on a dish
table or the like.
[0034] FIG. 4 additionally show the placement of an optional
heating element 37 under and in thermal contact with the bottom
wall of wash tank 16. While the primary function of the system of
the present invention may be pre-washing, it would still be
advantageous to maintain the wash fluid at an elevated temperature
in some circumstances. Heating element 37 should, as with the
balance of the electrical components of the system adjacent the
wash tank, be lower voltage DC powered to avoid any issues with
proximity to a wet environment. Regardless, heating element 16 is
preferably sealed against the bottom of wash tank 16 with no
exposed electrical connections near the base of the unit.
Alternatively, other heating element systems that might be extended
into wash tank 16 may also be incorporated into the design.
[0035] Reference is next made to FIG. 5 for a detailed perspective
front view of the three-basket embodiment of the silverware washing
system of the present invention with the wash tank, tank cover, and
center basket removed for clarity. System base 14 supports the
structured enclosures made up of enclosure cover 40, drive
mechanism cover (and support) 12, and lift mechanism cover 24.
Passing through enclosure cover 40 and through the rear wall of the
wash tank are a pair of sensors designed to collect data on the
level and condition of the wash fluid within the wash tank. Sensors
50a & 50b may serve to measure liquid level, temperature,
and/or total dissolved solids (TDS) within the wash fluid. Such
information assists in alerting the user as to the need to change
the wash fluid and/or add chemicals and/or modify the temperature
of the fluid. Heating element 37 is shown positioned as it would be
beneath the wash tank (not shown) even though it would, as
described above, typically be adhered to (and sealed against) the
bottom wall of the wash tank. Alternatively, a heating element of
the type that extends into the wash tank could also be used.
[0036] FIG. 5 shows in clearer detail the structure and function of
basket holder frame 28 and the three associated basket holders
30a-30c. Left basket 20c is shown positioned fully within left
basket holder 30c while the center basket is removed for clarity
from center basket holder 30b. Right basket 20a is shown removed
from right basket holder 30a being lifted vertically up from the
holder. Each basket is preferably structured with a perimeter lip
that rests on the appropriately sized ring of the aligned basket
holder. Once again, each basket preferably includes one or more
handles to facilitate the placement into or removal from the
associated basket holder.
[0037] Although the embodiment shown herein uses three baskets that
are structured to be raised and lowered in unison, the same basic
principles for pre-washing and/or washing silverware positioned in
baskets that move in opposite directions can be applied. With the
appropriate linkages in the drive and lift mechanisms, along with
separated basket holder frames, it is possible to implement the
reciprocating up and down motion of each basket at different points
in the cycle. In the embodiment shown, for example, one basket
holder frame might be associated with the left and right baskets
while a separate basket holder frame would be associated with the
center basket. Such a structure would require two separate lift
rods linked to separate actuator rods although each could still
operate through a single bearing block and could be driven by a
single (two arm) crank. The rates of reciprocating motion,
regardless of whether the baskets were moving in unison or not, can
be controlled and varied by a programmable controller (described
below) positioned remote from the unit shown that sits on the
tabletop. As mentioned above, LED indicators 19a & 19b
positioned on the front facing wall of lift mechanism cover 24,
provide cycle process status information to the user to further
optimize ongoing use of the system without having to simply stop
and start the operation to load or unload silverware.
[0038] Reference is next made to FIGS. 6A & 6B for clearer
depiction of the manner of raising and lowering the baskets into
the wash fluid. FIG. 6A is a centerline cross-sectional view of the
three-basket embodiment of the silverware washing system of the
present invention with the lifting mechanism in a raised condition.
FIG. 6B is the same centerline cross-sectional view with the
lifting mechanism in a lowered condition. Drive mechanism cover
(and support) 12 and lift mechanism cover 24 are shown in place as
they each enclose the drive and lift components of the system.
Bearing block 38 (for example) is seen to be supported by the top
of drive mechanism cover 12 where the cover extends forward over
the tank cover 18. The drive components (DC motor 42, gear box 46,
and crank arm 44) are positioned with the appropriate clearances
within drive mechanism cover (and support) 12. The lift components
(lift rod 36, lift rod connector 34, and actuator rods 32) are
positioned with the appropriate clearances within the lift
mechanism cover 24.
[0039] Wash tank 16 is seen in cross-section as it is supported on
system base 14 (the base fitted with a plurality of base rubber
feet 35) with heating element 37 adhered to the bottom exterior
surface of the wash tank. Sensor 50b and tank fluid line 49 are
shown in this view as they extend through the back wall of wash
tank 16 from outside the tank. Tank fluid line 49 directs wash
fluid 17 to flow into wash tank 16 from auto fill valve 48 (and
optionally through the chemical inductor or other chemical mixing
system). LED indicators 19a & 19b are again visibly positioned
on lift mechanism cover to provide process cycle information to the
user. LED indicator 21b is associated with center basket 20b
positioned in center basket holder 30b to assist the user with
identifying a proper basket loading sequence. Each of these LEDs
are driven by the remote (wall mounted) controller described in
more detail below.
[0040] In the cross-sectional view of FIGS. 6A & 6B, the manner
in which tank cover 18 extends downward into wash tank 16 is
apparent. In addition to partially covering the open top of wash
tank 16, tank cover 18 forms three cylindrical columns within which
the baskets and basket holders vertically move. The wash fluid
level in the wash tank preferably comes up to the bottom edge of
the cylindrical columns formed by the tank cover that surround each
basket and basket holder. This configuration forces the fluid to
predominantly flow vertically through the silverware in the basket
as opposed to off the silverware and over through the sides of the
basket. The cylindrical columns also reduce splashing as the
baskets are immersed into the wash fluid and/or lifted up from the
wash fluid. The system as described is designed to operate
optimally with the wash tank about half full of wash fluid. The
exact depth of the wash tank and location of the water line is
variable for achieving multiple washing objectives. This allows the
baskets to be alternately fully submersed into and fully removed
from the wash fluid. The relatively turbulent flow of fluid through
the randomly oriented silverware positioned in the baskets provides
an effective, powerful pre-wash more than adequate for most
commercial food service facility applications.
[0041] FIG. 6B provides the same cross-sectional view as that shown
in FIG. 6A but with the basket and lift mechanism in the lowered
and immersed condition. In this view, actuator rods 32 have
travelled downward to their limit where lift rod connector 34 is
adjacent to the top of bearing block 38 and basket holder frame 28
approaches the bottom of wash tank 16. In this condition, any
silverware in center basket 20b is nearly fully immersed in wash
fluid 17 as center basket holder 30b ends up at approximately the
wash fluid surface. It should be noted that the crank arm
configuration allows for the continuous rotation of the gears in
gear box 46 in one direction to drive the reciprocating up and down
motion to the baskets. In order to reduce wear on the drive system,
the DC motor can be easily reversed by the controller in order to
reverse the direction of the gear box and crank arm rotation while
not altering the essential reciprocating vertical motion of the
baskets.
[0042] FIGS. 7A & 7B provide alternative installations of the
system of the present invention dependent on the availability of
plumbed water lines and the use of chemical additives to the wash
fluid. While each figure shows the installation of two systems of
the present invention, similar installations can be implemented
with only a single system or with more than two systems. In each
installation, the food service facility is presumed to have a dish
table/stand 56 which may or may not be positioned adjacent an open
facility wall 58. Many other practical arrangements may be made
depending on the dish room table layouts in various foodservice
outlets where the systems would be installed.
[0043] FIG. 7A is a perspective view of a typical installation of
two of the silverware washing systems of the present invention in a
food service facility where an adjacent fill faucet is available
for use. A first wash system 60a is positioned next to a second
wash system 60b on the top surface of dish table/stand 56 in front
of facility wall 58. Fill faucet 57 is preferably centered between
the two systems such that a pivoting faucet neck can alternately
swing over the two systems to supply wash water into the respective
wash tanks. Positioned above the two systems 60a & 60b on wall
58 is control box 64. External power connection 65 provides AC
power to control box 64 where controller/DC power source 66
connects to each of the systems by way of power and control cables
62a & 62b. Control box 64 provides the necessary user interface
to not only switch the respective systems on and off but also to
direct the cyclical process of operation for each of the
systems.
[0044] FIG. 7B is a perspective view of an alternate installation
of two of the silverware washing systems of the present invention
in a food service facility with plumbed water supply lines and the
use of chemical additive reservoirs. In this alternate
installation, a first wash system 60a is again positioned next to a
second wash system 60b on the top surface of a dish table/stand 56
in front of facility wall 58. Positioned above the two systems 60a
& 60b on facility wall 58 is control box 64. As above, external
power connection 65 provides AC power to control box 64 where
controller/DC power source 66 connects to each of the systems by
way of power and control cables 62a & 62b. In place of a fill
faucet, however, this installation incorporates the auto fill
features of the system shown and described above in FIG. 3. Water
supply lines 69a & 69b connect each system 60a & 60b
respectively to external water supply 70. Water supply lines 69a
& 69b preferably incorporate separate manual cutoff valves (not
shown) as a manner of controlling the flow of water to each system
in addition to the auto fill valve configured within each
system.
[0045] The installation shown in FIG. 7B also incorporates the
optional chemical additive feed process shown and described above
in FIG. 3 and further described in FIG. 8 below. Chemical
supply/reservoirs 68a & 68b connect to each system 60a &
60b respectively to provide a venturi vacuum induced flow of
chemical additive to the wash fluid through the above described
chemical feed line 23 and chemical inductor 45 (not visible in FIG.
7B).
[0046] As mentioned, the basic system of the present invention only
requires connection to an external power source, preferably a
standard AC power source, to operate through the described wall
mounted controller/DC power source. More specifically, and
preferably, a 100 to 240 volt AC power connection (50 or 60 Hz) is
supplied and an internal power converter inside the control panel
coverts that power to low voltage DC power (12, 24, 48 volts DC
etc.). The additional (optional) connection to a plumbed external
water supply allows for the use of the auto fill functionality of
the system and the additional (optional) connection to a chemical
reservoir allows for the use of various chemical additives in the
wash fluid. Further external connections could include a common
drain line with or without automating the activation of the
described drain valves on each system.
[0047] FIG. 8 is a detailed perspective rear view of the drive and
lift mechanisms of the system of the present invention with the
covers removed for clarity. Once again, the functional components
of the drive and lift mechanisms are exposed where they are
positioned and secured within the drive mechanism cover (and
support) 12. Actuator rods 32 are positioned through bearing block
38 and extend downward to their point of attachment to the basket
holder frame inside of the wash tank. The top ends of actuator rods
32 are pivotally connected to lift rod 36 which serves as the
linkage between the drive mechanism of the system and the lift of
the system. DC motor 42 is powered from an external source,
preferably from a centralized remote (wall mounted) controller as
shown and described below in FIG. 9. This power and control
connection has been omitted for clarity from FIG. 8 but comprises
one of the system cables 62a & 62b shown in FIGS. 7A & 7B.
DC motor 42 drives the gears within gear box 46 which turn crank
arm 44 which is pivotally linked to lift rod 36. The rotational
motion of crank arm 44 translates into the vertical motion of lift
rod 36 and through such linkage to the vertical motion of the
actuator arms 32. As described above, the reciprocating vertical
motion of the actuator arms 32 provide the same cycling vertical
motion to the baskets in and out of the wash fluid. DC motor 25 is
preferably a variable speed reversable motor whose speed and
direction can be controlled by the controller/DC power source shown
in FIGS. 7A & 7B.
[0048] Further shown in FIG. 8 is external water line 47 which may
be connected to an available external water source to provide a
controlled filling of the wash tank of the system. In the preferred
embodiment, external water line 47 is preferably attached to the
system through auto fill valve 48. Auto fill valve 48 is preferably
an electric solenoid actuated valve that may be controlled (on and
off) by the same controller that powers the DC motor 42. In one
embodiment of the system of the present invention, auto fill valve
48 may connect directly to wash tank 16, delivering "tap water"
into the system. Alternately, as shown in FIG. 8, the flow of water
may pass first through chemical inductor 45 before flowing into
wash tank 16. Chemical inductor 45 receives a controlled flow of
chemical additive from a remote reservoir by way of chemical feed
line 23. Control of the venturi vacuum induced flow of chemical
additive may occur through the use of a valve (automated or manual)
associated with the system as previously noted.
[0049] In addition to controlled power to the DC motor and the
solenoid actuated water valve, the cable connections between the
individual wash units and the centralized controller would include
signal lines directing the operation of the various LED indicators
as well as signal lines receiving data from the various wash fluid
condition sensors. Once again, the basic functionality of the
system requires only power to the DC motor in the system while the
optional functionalities of automated water flow, chemical
additive, fluid condition measurements, and operational indicators
may all be added individually or collectively to further improve
operation of the system.
[0050] Reference is finally made to FIG. 9 which is a detailed
perspective view of the control elements of a typical installation
of two of the silverware washing systems of the present invention
in a food service facility, in this case with an adjacent fill
faucet 57. Control box 64 is mounted on facility wall 58 and is
connected to the individual units (represented by wash system 60b
in FIG. 9) by way of system cables 62a & 62b respectively.
Power to controller/DC power source 66 within control box 64 is
provided by external power connection 65. In this view, control box
64 is shown to include audible alarm 63 and communications port 67
that provide additional functionality to the system in the manner
of user interface and wide area network connectivity. Audible alarm
63, as driven by controller/DC power source 66, serves to alert the
user to a condition in one or more of the attached systems that
requires attention. This could be anything from a cycle completion
event to a low wash fluid level within the system. Controller/DC
power source 66 preferably includes an informational display that
facilitates both user control of the systems (such as with a
touchscreen display) and the display of the conditional status of
the systems. Communications port 67 is preferably a standard USB
port that allows for both the transmittal of operational data from
the controller and the receipt of programming for system operation
to the controller. Such transmission and receipt of digital
information and programming may be wired or wireless as is known in
the art as the USB port can also be used as a connection point for
a Wi-Fi, Bluetooth, or cellular communication module.
[0051] Although the present invention has been described in
conjunction with a number of preferred embodiments, those skilled
in the art will recognize modifications to these embodiments that
still fall within the spirit and scope of the invention. Because of
the ability of the system of the present invention to function as a
standalone unit without extensive space and/or ancillary plumbing,
a variety of commercial kitchen table units may be used to support
the system. Alternately, the present invention may be implemented
with the manufacture of concurrently produced platform sized and
structured to accommodate the dimensions of one or more of the
proprietary systems. The invention has been described in terms of a
basic embodiment with a number of add-on functionalities that may
be implemented separately or collectively. Further add-on
functionalities will be anticipated by those skilled in the art
that do not depart from the spirit and scope of the invention as
set forth in the appended claims.
* * * * *